Integration of Thermochemical Heat Storage System with Waste heat Recovery Systems

ABSTRACT

A waste heat recovery for use with refrigeration means and space heating/water heating to meet various seasonal demands on refrigeration and heating energy is disclosed. The system is intended for use with refrigeration means of the conventional type including a compressor and a condenser through which a compressible refrigerant is circulated. The system integrates a refrigeration system and a heating utilization system through a thermochemical system functioning as a heat transfer system and thermochemical energy storage system. Wherein the heat transfer system is used for absorbing the waste heat normally dissipated in the condenser and for discharging the recovered thermal energy to a heat utilization system for space heating and/or water heating, the thermochemical energy storage system is used for converting the waste heat collected into chemical energy for seasonal storage. The waste heat recovery system is designed with a feature that operations of the refrigeration system and the heat utilization system are de-coupled so that the refrigeration system and the heat utilization system can be operated independently at different times on demand. This feature makes implementation of the waste heat recovery system viable for more residential houses, commercial establishments, and industrial processes applications.

FIELD OF THE INVENTION

The present invention relates generally to waste heat recovery system from air conditioning/refrigeration system, in particular relates to such system which recovers the heat wasted during operations of an air conditioning or a refrigeration system, stores the recovered heat in form of chemical energy and releases the stored energy for purpose of water heating and/or space heating as being demand for up to months, event in different seasons.

DESCRIPTION OF THE PRIOR ART

The waste heat recovery from refrigeration systems or air conditioning systems has been studied for many years. However, the waste heat recovery techniques investigated so far are economically feasible for implementation only in industrial refrigeration systems having a large capacity compressor through which large volumes of refrigerant gas are circulated to a condenser, and practical uses of waste heat from refrigeration systems are typically limited to space heating and water heating used for associated industrial processes due to low quality, low temperature of the recovered waste heat. Attempts have been made to more effectively utilize the waste heat from industrial refrigeration systems using various other techniques, such as use of waste heat to drive heat pumps for space heating and/or cooling, to preheat the regeneration air flow used in solid desiccant adsorption dehumidification systems or to preheat the liquid desiccant in absorption dehumidification system, to produce power, cooling and heating by use of tri-generation or combined cooling, heat and power (CCHP), or to generate electrical power by applying fuel cell technology in order to effectively utilize the resulting waste heat.

It has been noted that all these techniques have a common feature that they have to be operated simultaneously in a real time on-line process, meaning that the waste heat recovered has to be consumed simultaneously or immediately after being recovered or consumed in the associated ongoing processes since no efficient and cost-effective heat preserve means are available and implemented. That means that operations of the waste heat utilization systems have to match with the operations of the waste heat recovery systems. The mismatching between the available heat supply and demand will limit the operation capabilities of those systems. That is one of the key factors limiting the implementation of those techniques for waste heat recovery from refrigeration and air conditioning systems. Another limiting factor is the system capacity requirements since only in industrial refrigeration systems or air conditioning systems having a large compressor capacity, sufficient amount of waste heat can be recovered for practical applications so to make those waste heat recovery techniques viable for practical implementation.

To expand the applications of those waste heat recovery techniques, it is desirable to find an effective means to accumulate the recovered heat for storage and to de-couple the operations of waste heat recovery system and waste heat utilization system, meaning that a waste heat recovery system and the associated waste heat utilization system can be operated ‘off-line’ on demand when needed, or they do not have to be operated simultaneously, the recovered waste heat can be accumulated and stored efficiently with minimum heat loss or even without loss, and can be used at any time on demand as needed. That would make all available waste heat recovery techniques more implementable, particularly for air conditioning systems, they are being heavily operated in hot (summer) seasons, but not in operation in cold (winter) seasons; having large or small capacity.

SUMMARY OF THE INVENTION

It is a principal objective of the present invention to provide a method and a systems for de-coupling the operations of waste heat recovery and the waste heat utilization system which can be applied to the currently existing and widely used conventional refrigeration systems or air conditioning systems in order to make the implementation of waste heat recovery techniques more viable for the applications in residential houses, commercial establishments and industrial processes.

Another objective of the present invention is to provide a method and a system that the recovery waste heat can be accumulated and stored efficiently with minimum heat loss or even without energy loss.

Additional objective of the present invention is to provide a method and a system that the heat energy stored in the system can be released at any time on demand when needed.

A further objective of the present invention is to provide a method to integrate the waste heat recover/transfer system, the heat energy storage system and the heat utilization system into an practical usable waste heat recovery system which can be applied to most sizes of refrigeration systems or air conditioning systems in domestic residential homes, commercial establishments and industrial processing applications.

The essence of the present invention is to utilize a thermochemical storage (TCS) system to provide a method for integration of a waste heat transfer system from refrigeration system or air conditioning system and a heat utilization system. A thermochemical storage (TCS) system is to be used for de-coupling operations of the waste heat transfer system and the utilization system, for accumulating and storing the recovered waste heat for periods of up to several months with minimum heat loss or without heat loss at uncontrolled ambient temperature conditions and for releasing the stored waste heat recovered for space heating and water heating for domestic residential houses, commercial establishments and industrial process applications.

The TCS system disclosed in the present invention is based on the salt hydrate technology, the system uses the reaction energy created when salts are hydrated or dehydrated (endothermic/exothermic chemical reaction). It works by storing heat in a vessel containing suitable wet salt. Heat (recovered from refrigeration or air conditioning system) is converted and stored in form of chemical energy by evaporating the water in an endothermic reaction. When water is added again, heat is released in an exothermic reaction. The TCS is a compact way to store heat for a longer time without typical heat losses. This makes it an appropriate solution to overcome the mismatch between seasonal heat supply and demand in temperate climate zones.

These and other objects, features, and advantages of the present invention will become more readily apparent from the attached drawings and from the detailed description of the preferred embodiments, which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary schematic diagram of an integrated waste heat recovery system constructed according to the teaching of the present invention which includes subsystems of refrigeration or air conditioning system, the waste heat transfer system, the thermochemical storage (TCS) system and the waste heat utilization system, and,

FIG. 2 illustrates a configuration of a module containing thermochemical material (TCM) used for either substituting the condenser in a conventional refrigeration or air conditioning system (as shown in FIG. 3) or being added between the compressor and condenser in a conventional refrigeration or air conditioning system (as shown in FIG. 1). The drawing is for illustration purpose, does not reflect an actual arrangement and a number of piping runs inside a module.

FIG. 3 is an alternation of the integrated waste heat recovery system as shown in FIG. 1, in which the chermochemical material (TCM) is used to replace the condenser completely in a conventional refrigeration or air conditioning system, instead of being added between the compressor and the condenser.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

In the description which follows, like parts are marked throughout the drawing with the same reference numerals respectively.

Referring now to FIG. 1 of the drawing, the waste heat recovery system of the present invention includes an integration of four subsystems: a conventional air conditioning or refrigeration system, a waste heat transfer system, a thermochemical storage system and a waste heat utilization system.

The conventional air conditioning or refrigeration system consists of an evaporator 1, a compressor 2, a condenser 3, and a throttle 4, they are suitably sized and interconnected to provide air conditioning for a residential house or refrigeration for a commercial establishment such as a show case in a supermarket or refrigeration for an industrial process such as food processing. Air to be conditioned is brought into heat exchanger relation with the evaporator 1 by means of suitable circulation equipment (not shown) into the area being conditioned. An outside fan (not shown) brings outside air into heat exchanger relation with the condenser 3 (3′ TCM module is not in normal air conditioning system). In operation, liquid refrigerant flows from the condenser 3 through the capillary tube (not shown) into the evaporator 1. The pressure of the liquid refrigerant as it enters the capillary tube is at a high pressure, while the pressure in the evaporator 1 is at a low pressure, suitable designed capillary tube maintains a pressure difference while the compressor 2 is operating. The compressor 2 maintains a low pressure in the evaporator coil and the refrigerant boils rapidly thereby absorbing heat from the evaporator coils as air passes through. The vaporized refrigerant is drawn through the suction line back to of the compressor 2 where it is compressed to a high pressure and subsequently discharged into the condenser coils where it is cooled by the flow of outside air and returns to a liquid. Thus the liquid refrigerant absorbs heat while changing from its liquid state to a vapor state in the evaporator 1 and gives up heat while changing from its vapor state to a liquid state in the condenser 3. The heat given up by the refrigerant in the condenser 3 is taken away by outside air passing through the condenser 3 and dissipated into environment.

In order to recover the waste heat energy dissipated in the condenser 3, the air conditioning or refrigeration system is modified according to the present invention by incorporating a waste heat transfer system into the air conditioning or refrigeration system in three ways:

-   -   1) Inserting a waste heat transfer system between the compressor         2 and the condenser 3 (as shown in FIG. 1);     -   2) Installing a waste heat transfer system between the         compressor 2 and the condenser 3, which is suitably downsized in         its capacity (refer to FIG. 1);     -   3) Replacing the condenser 3 completely with a waste heat         transfer system—a TCM module 3′ (as shown in FIG. 3);

The waste heat transfer system is used to recover the waste heat that is normally dissipated to the environment in the condenser 3 of a conventional air conditioning or refrigeration system. The waste heat recovery is achieved through wet salt dehydration process according to the present invention. A suitably selected salt (thermochemical material—TCM) is packed in a container (named as TCM module 3′ in the later description of this application), wet salt in TCM module 3′ located either at the position of the condenser 3 (replacing the condenser as shown in FIG. 3) or inserted between the compressor 2 and the condenser 3 (as shown in FIG. 1) is working in a closed system under sub atmospheric pressure (vacuum) conditions. The recoverable heat associated with hot refrigerant gases produced by refrigeration compressor 2 is taken as input for desorption—the high temperature heat source. The water contained in the wet salt in TCM is being heated and dehydrated, and the produced vapor is led to a water condenser/evaporator 5 and condensed into water by cooling to maintain the vacuum condition in the water condenser/evaporator 5, the cooling water is being taken by the pump 8 from the reservoir 7 as the low temperature heat source in the closed system through valve 12 and valve 13 (opened). The amount or the level condensed water in the water condenser/evaporator 5 is controlled by the valve 10, when the condensed water exceeds the predetermined amount or level, water is led into a water tank 6 through the valve 10. During this process, valve 14 and valve 15 can be closed so that hot water tank 9 and other heating appliances (not shown) can be isolated from the waste heat transfer system or the waste heat recovery process. The configuration of the TCM module 3′, the refrigerant passage in relation to the salt within the module and the waste heat transfer process are illustrated in more detail in FIG. 2 of the drawing.

The thermochemical storage system is used to accumulate and to store the recovered heat energy. Heat energy is stored inside the TCM module 3′. The recovered heat from hot refrigerant gas is converted as chemical energy through the salt dehydration process and stored in the form of drier salt contained in the TCM module 3′, and kept for use on demand when needed.

For selection of the appropriate salt, the following salt properties should be considered: safety (if the salt is toxic), energy density, hydration temperature and dehydration temperature, melting point, deliquescence vapor pressure, chemical instability, hydration and dehydration kinetics, etc. A guideline for selection of suitable salt is provided in the cited reference,—Donkers et al. “A review of salt hydrates for seasonal heat storage in domestic applications” Applied Energy. The type of modifications for the waste transfer system and the TCM module design as described in FIG. 2 should be also taken into account. In the exemplary embodiment of the present invention, sodium thiosulfate (Na2S2O3) was chosen.

Modularity should be also considered as incorporated in the exemplary embodiment design. Since the salt is contained in a TCM module, when the wet salt in the TCM module is fully or near fully dehydrated, the module can be dismounted from the system and a new module containing fresh wet salt to be dehydrated can be installed into the system so that the waste heat recovery process can be maintained continuously with the operations of the air conditioning or refrigeration operation of the system.

The waste heat utilization system is used to release the energy stored in the thermochemical storage (TCS) system on demand, that is achieved through dry salt hydration process. Water in tank 6 is fed through the valve 11 into the TCM module 3′, the dry salt within the module reacts with water and generates heat and water vapor, which is led into the water condenser/evaporator 5, heat is transferred to water driven by pump 8 through the opened valve 14 and 15, circulating between the water condenser/evaporator 5, hot water tank 9 and other heating appliances (consumers) down the lines in the system. During this process, valve 12 and valve 13 are closed, and functioning as isolation valves unless the system needs refills with feeding water.

With this arrangement, it will be seen that the operations of the waste heat transfer system and the waste heat utilization system can be isolated or de-coupled through the controlling the pump 8, the valve 10, 11, 12, 13, 14, 15, temperature sensing and switching devices, flow meters or level sensing and control devices installed in various positions (not shown), these devices are commercially available in the electronic products markets by various suppliers.

Similar to the dehydration process, modularity incorporated into the exemplary embodiment design makes the system hydration operation more flexible. When the dry salt in the TCM module is fully or near fully hydrated, the module can be dismounted from the system and a new module containing fresh dry salt to be hydrated can be installed into the system so that the waste heat recovered previously can be released continuously through salt hydration process in the waste heat utilization system.

As illustrated in FIG. 2 of the drawing, the TCM module 3′ is constructed with a heat exchanger design that is constructed in cylindrical container 16 with a flat bottom and dismountable cover 17 for easy maintenance in the preferred embodiment of the present invention. Inside the container 16, refrigerant tubes 18 are finned (fin 20 as shown in FIG. 2) as heat exchanger blocks to increase heat transferring area and to provide support structure for holding packed TCM spheres 19 in which the spheres are fixed by using a composite material which is porous and permeable to water vapor.

The dimensions of the TCM modules, in turn the volume of TCM, the number and the arrangement of the heat exchanger blocks (in series or parallel) will be optimized based on the salt selected, the design temperature at refrigerant inlet and outlet, pressure drops and heat exchange calculations of the refrigerant circuits in the TCM module 3′, the characteristics of the air conditioning or refrigeration system, the number and capacities and types of the heating appliances (consumers) in the waste heat utilization system associated as well as modularity considerations should be taken into account.

Although the preferred embodiments have been elaborated above, it should be understood that the various changes, substitutions, alternations can be made therein without departing from the spirit and the scope of the invention as defined in the appended claims.

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What is claimed is:
 1. A heat recovery system for recovering waste heat from refrigeration mean for space heating and water heating comprising: a. A conventional refrigeration mean; b. A waste heat transfer system; c. A thermochemical heat storage system; d. A heat utilization system.
 2. The heat recovery system for recovering waste heat from refrigeration mean for space heating and water heating as cited in claim 1, wherein said refrigeration means includes a compressor, a condenser, a throttle and an evaporator; the modifications including the methods of: a. Inserting a waste heat transfer system/module (TCM Module) between the compressor and the condenser; b. Installing a TCM Module as cited in claim 2a, and changing said condenser with a suitably designed and reduced capacity; c. Replacing said condenser as cited in claim 2a, with a suitable designed TCM Module.
 3. The heat recovery system for recovering waste heat from refrigeration mean for space heating and water heating as cited in claim 1, wherein said waste heat transfer system comprising: a. At least a thermochemical heat storage module (TCM module); b. At least a water condenser/evaporator connected to said TCM module; c. At least a water tank connected to said water condenser/evaporator through a controlling valve for regulating water level in said water condenser/evaporator and connected to said TCM module through another controlling valve for feeding water for salt hydration; d. At least a pump supplying cooling water in circulation to said water condenser/evaporator; e. A reservoir or a ground storage connected to said pump and said water condenser/evaporator for cooling water supply.
 4. The heat recovery system for recovering waste heat from refrigeration mean for space heating and water heating as cited in claim 1, wherein said thermochemical heat storage system comprises a thermochemical heat storage module (TCM module), containing: a. At least a container with inlet and outlet openings for refrigerant, water and water vapor; b. Heat exchanger blocks formed with refrigerant tubes; c. Appropriately selected salt which is packed on said heat exchanger blocks as cited in 4b.
 5. The heat recovery system for recovering waste heat from refrigeration mean for space heating and water heating as cited in claim 1, wherein said heat utilization system comprising: a. At least a TCM module; b. At least a water condenser/evaporator connected to said TCM module; c. At least a water tank connected to said water condenser/evaporator through a controlling valve and to said TCM module through another controlling valve; d. At least a pump supplying circulating water to said water condenser/evaporator; e. At least a heat exchanger connected to said pump and said water condenser/evaporator and other possible heating appliances functioning as water heater.
 6. The heat recovery system for recovering waste heat from refrigeration mean for space heating and water heating as cited in claim 1, wherein said integrated waste heat recovery system comprising: a. Valves located in various positions in the piping system and being controlled by means of an apparatus (control system) so that the operations of the said waste heat transfer system and the said utilization system can be isolated or de-coupled, i.e. the said two systems do not have to be operated simultaneously; b. An apparatus (control system) as cited in claim 6a comprising controlling modules and various sensing and switching devices (temperature, pressure, water level) at various locations of the piping systems. 